Optimization of Friction Stir Welding of Al–Cu Butt Joint Using Taguchi Method

In this work, the 5 mm thickness of base metals AA6101 and C11000 was welded using a hardened OHNS steel tool by FSW mechanism. The Taguchi method involves the optimization of welding mechanism variables tool rotation speed (rpm), feed rate (mm/min), and tool offset (mm) to gain extremely rigid joints. The ANOVA reveals the percentage contribution of the three welding mechanism variables can be examined. From the Taguchi design of optimization technique, at 1000 rpm, 40 mm/min, and tool offset towards softer metal will possess maximum impact load. The tool’s rotating speed produced the greatest contribution to the impact load.